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Komatsu D275AX-5E0 Crawler Bulldozer Shop Manual SEN00919-14 – PDF DOWNLOAD
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Description
Komatsu D275AX-5E0 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D275AX-5E0 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D275AX-5E0
Serial Number: 30001 and up
Book Code: SEN00919-14
Language: English
Pages: 1569
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D275AX-5E0 Crawler Bulldozer Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu D275AX-5E0 Crawler Bulldozer Shop Manual
COVER .............................................................................................................................. 1 00 Index and foreword............................................................................................................... 0 Index........................................................................................................................... 3 Composition of shop manual.................................................................................................. 4 Table of contents........................................................................................................... 6 Foreword and general information................................................................................................ 19 Safety notice............................................................................................................... 20 How to read the shop manual................................................................................................. 25 Explanation of terms for maintenance standard............................................................................... 27 Handling of electric equipment and hydraulic component...................................................................... 29 Handling of connectors newly used for engines............................................................................... 38 How to read electric wire code.............................................................................................. 41 Precautions when carrying out operation..................................................................................... 44 Method of disassembling and connecting push-pull type coupler............................................................... 47 Standard tightening torque table............................................................................................ 50 Conversion table............................................................................................................ 54 01 Specification.................................................................................................................... 0 Specification and technical data................................................................................................ 61 Specefication dimension drawings............................................................................................ 62 Specifications.............................................................................................................. 64 Weight table................................................................................................................ 76 Table of fuel, coolant and lubricants....................................................................................... 80 10 Structure, function and maintenance standard..................................................................................... 0 Engine and cooling system....................................................................................................... 83 Engine mount................................................................................................................ 84 Cooling system.............................................................................................................. 86 Cooling fan pump............................................................................................................ 88 Cooling fan motor........................................................................................................... 96 Power train, Part 1............................................................................................................. 103 Power train skeleton........................................................................................................ 104 HSS system.................................................................................................................. 106 Overall drawing of power train unit......................................................................................... 108 Power train hydraulic piping drawing........................................................................................ 110 Transmission control........................................................................................................ 111 Steering, brake control..................................................................................................... 112 Damper, universal joint..................................................................................................... 114 Torque converter, PTO....................................................................................................... 116 Transmission................................................................................................................ 130 Tranmission ECMV............................................................................................................ 142 Main relief valve and torque convertor relif valve.......................................................................... 148 Torque converter valve...................................................................................................... 152 Lubrication relief valve.................................................................................................... 160 Power train system, Part 2...................................................................................................... 163 Bevel gear shaft, HSS, brake................................................................................................ 165 Brake valve................................................................................................................. 178 Brake ECMV.................................................................................................................. 179 Parking brake valve......................................................................................................... 185 Sudden brake prevention valve............................................................................................... 186 Final drive................................................................................................................. 187 Sprocket.................................................................................................................... 192 Undercarriage and frame......................................................................................................... 195 Track frame................................................................................................................. 196 Idler cushion............................................................................................................... 200 Idler....................................................................................................................... 204 Track roller................................................................................................................ 206 Track roller bogie.......................................................................................................... 208 Carrier roller.............................................................................................................. 210 Track shoe.................................................................................................................. 212 Main frame.................................................................................................................. 216 Suspension.................................................................................................................. 218 Hydraulic system, Part 1........................................................................................................ 227 Work equipment hydraulic piping diagram..................................................................................... 228 PPC control piping diagram.................................................................................................. 232 Work equipment control...................................................................................................... 234 Hydraulic tank.............................................................................................................. 236 Scavenging pump............................................................................................................. 238 Work equipment pump......................................................................................................... 240 Power train pump, steering lubrication pump................................................................................. 256 HSS pump.................................................................................................................... 257 HSS motor................................................................................................................... 273 PPC, HSS charge filter...................................................................................................... 282 Hydraulic system, Part 2........................................................................................................ 285 Control valve............................................................................................................... 286 Self pressure reducing valve................................................................................................ 315 Hydraulic system, Part 3........................................................................................................ 323 HSS charge filter bypass.................................................................................................... 324 HSS oil cooler bypass valve................................................................................................. 326 PPC valve................................................................................................................... 328 PCCS lever.................................................................................................................. 340 PPC lock valve.............................................................................................................. 343 Hydraulic cylinder.......................................................................................................... 344 Piston valve................................................................................................................ 350 Quick drop valve............................................................................................................ 351 Pin puller switch........................................................................................................... 352 Pin puller solenoid valve................................................................................................... 353 Blade control knob.......................................................................................................... 355 Pitch, dual tilt solenoid valve............................................................................................. 356 Accumulator................................................................................................................. 357 Work equipment.................................................................................................................. 359 Cylinder stay............................................................................................................... 360 Blade....................................................................................................................... 362 Ripper...................................................................................................................... 368 Cab and its attachments......................................................................................................... 371 Cab and its attachments..................................................................................................... 372 Cab mount............................................................................................................... 372 Cab..................................................................................................................... 373 Air conditioner......................................................................................................... 375 Electrical system............................................................................................................... 377 Engine control system....................................................................................................... 378 CRI engine control system................................................................................................... 388 Monitor system.............................................................................................................. 390 Machine monitor............................................................................................................. 392 Mode selection system....................................................................................................... 406 Sensors..................................................................................................................... 410 Electrical equipment........................................................................................................ 416 Palm command control system................................................................................................. 418 KOMTRAX system.............................................................................................................. 420 20 Standard value table............................................................................................................. 0 Standard service value table.................................................................................................... 423 Standard value table for engine............................................................................................. 424 Standard value table for machine............................................................................................ 425 30 Testing and adjusting............................................................................................................ 0 Testing and adjusting, Part 1................................................................................................... 433 Tools for testing, adjusting, and troubleshooting........................................................................... 435 Testing engine speed........................................................................................................ 438 Testing intake air pressure (Boost pressure)................................................................................ 441 Testing exhaust temperature................................................................................................. 443 Testing exhaust gas color................................................................................................... 445 Adjusting valve clearance................................................................................................... 447 Testing compression pressure................................................................................................ 449 Testing blow-by pressure.................................................................................................... 451 Testing engine oil pressure................................................................................................. 452 Testing EGR valve and bypass valve drive oil pressure....................................................................... 453 Handling of fuel system devices............................................................................................. 454 Releasing residual pressure from fuel system................................................................................ 454 Testing fuel pressure....................................................................................................... 455 Testing fuel return rate and fuel leakage................................................................................... 456 Bleeding air from fuel circuit.............................................................................................. 460 Testing fuel circuit for leakage............................................................................................ 462 Testing and adjusting alternator belt tension............................................................................... 463 Handling controller voltage circuit......................................................................................... 464 Testing and adjusting air conditioner compressor belt....................................................................... 465 Testing fan speed........................................................................................................... 466 Testing fan circuit oil pressure............................................................................................ 467 Bleeding air from fan pump.................................................................................................. 468 Adjusting fuel control dial and decelerator pedal........................................................................... 469 Testing and adjusting, Part 2................................................................................................... 473 Testing power train oil pressure............................................................................................ 475 Testing and adjusting HSS oil pressure...................................................................................... 484 Adjusting transmission speed sensor......................................................................................... 489 Bleeding air from HSS pump.................................................................................................. 490 Simple method of testing brake performance.................................................................................. 490 Adjusting brake pedal and parking brake lever............................................................................... 491 Adjusting PCCS lever console position....................................................................................... 494 Emergency escape method when power train has trouble........................................................................ 495 Adjusting clearance of idler................................................................................................ 498 Inspecting wear of sprocket................................................................................................. 498 Testing and adjusting track shoe tension.................................................................................... 499 Testing and adjusting worke quipment oil pressure........................................................................... 500 Testing control circuit main pressure....................................................................................... 504 Testing PPC valve output pressure........................................................................................... 505 Adjusting play of PPC valve................................................................................................. 507 Testing outlet pressure of ripper pin puller solenoid valve................................................................. 510 Testing parts which cause hydraulic drift of blade and ripper .............................................................. 511 Testing internal leakage of work equipment cylinder......................................................................... 512 Releasing residual pressure from work equipment cylinder.................................................................... 513 Bleeding air from work equipment cylinder................................................................................... 513 Adjusting ripper lever position............................................................................................. 514 Adjusting work equipment lock lever......................................................................................... 515 Adjusting blade............................................................................................................. 516 Testing and adjusting operator’s cab........................................................................................ 520 Testing and adjusting, Part 3................................................................................................... 523 Special functions of machine monitor (EMMS)................................................................................. 524 Testing and adjusting, Part 4................................................................................................... 575 Adjustment method when controller has been replaced......................................................................... 576 Method of starting use of KOMTRAX terminal.................................................................................. 578 Indication by KOMTRAX terminal lamps........................................................................................ 581 Preparation work for troubleshooting for electric system.................................................................... 584 Handling of optional devices................................................................................................ 587 Pm Clinic service........................................................................................................... 588 40 Troubleshooting.................................................................................................................. 0 Failure code table and fuse locations........................................................................................... 599 Failure codes table......................................................................................................... 600 Fuse locations.............................................................................................................. 608 General information on troubleshooting.......................................................................................... 615 Points to remember when troubleshooting..................................................................................... 616 Sequence of events in troubleshooting....................................................................................... 617 Check before troubleshooting................................................................................................ 618 Classification and procedures for troubleshooting........................................................................... 619 Contents of troubleshooting table........................................................................................... 622 Connection table for connector pin numbers.................................................................................. 624 T- branch box and T- branch adapter table................................................................................... 660 Troubleshooting by failure and error codes, Part 1.............................................................................. 665 Failure code [1500L0] Transmission clutch dual engagement................................................................... 667 Failure code [15SAL1] Forward clutch oil pressure 1......................................................................... 668 Failure code [15SALH] Forward clutch oil pressure 2......................................................................... 670 Failure code [15SBL1] Reverse clutch oil pressure 1......................................................................... 672 Failure code [15SBLH] Reverse clutch oil pressure 2......................................................................... 674 Failure code [15SEL1] 1st clutch oil pressure 1............................................................................. 676 Failure code [15SELH] 1st clutch oil pressure 2............................................................................. 677 Failure code [15SFL1] 2nd clutch oil pressure 1............................................................................. 678 Failure code [15SFLH] 2nd clutch oil pressure 2............................................................................. 679 Failure code [15SGL1] 3rd clutch oil pressure 1............................................................................. 680 Failure code [15SGLH] 3rd clutch oil pressure 2............................................................................. 681 Failure code [1800MW] Power train clutch slip............................................................................... 682 Failure code [2300NR] Brake thermal load.................................................................................... 683 Failure code [2301L1] Right steering brake oil pressure 1................................................................... 684 Failure code [2301LH] Right steering brake oil pressure 2................................................................... 686 Failure code [2301NR] Right steering brake thermal load..................................................................... 688 Failure code [2302L1] Left steering brake oil pressure 1.................................................................... 690 Failure code [2302LH] Left steering brake oil pressure 2.................................................................... 692 Failure code [2302NR] Left steering brake thermal load...................................................................... 694 Failure code [6001ZK] Failure code for design............................................................................... 694 Failure code [A000NS] Engine overheat....................................................................................... 695 Failure code [AA10NX] Air cleaner clogging.................................................................................. 696 Failure code [AB00MA] Battery charge abnormal............................................................................... 698 Failure code [B@BAZG] Eng oil press low..................................................................................... 700 Failure code [B@BAZK] Eng oil level low..................................................................................... 701 Failure code [B@BCNS] Eng coolant overheat.................................................................................. 702 Failure code [B@BCZK] Radiator coolant level low............................................................................ 702 Failure code [B@BEBF] Water gets mixed with fuel............................................................................ 703 Failure code [B@BFZK] Fuel level abnormal reduction......................................................................... 703 Failure code [B@CENS] Torque converter oil overheat......................................................................... 704 Failure code [B@CHZG] HSS charge oil pressure reduction..................................................................... 705 Failure code [B@CHZK] Power train oil oil level reduction................................................................... 705 Failure code [B@GAZK] Battery electrolyte level reduction................................................................... 706 Failure code [B@HANS] Hyd oil overheat...................................................................................... 706 Failure code [B@HAZK] Hydraulic oil level reduction......................................................................... 707 Troubleshooting by failure and error codes, Part 2.............................................................................. 709 Failure code [CA111] EMC critical internal failure.......................................................................... 712 Failure code [CA115] Eng Ne and Bkup speed sens error....................................................................... 714 Failure code [CA122] Chg air press sensor high error........................................................................ 716 Failure code [CA123] Chg air press sensor low error......................................................................... 718 Failure code [CA131] Throttle sensor high error............................................................................. 720 Failure code [CA132] Throttle sensor low error.............................................................................. 722 Failure code [CA135] Eng oil press sensor high error........................................................................ 724 Failure code [CA141] Eng oil press sensor low error......................................................................... 726 Failure code [CA144] Coolant temp sens high error........................................................................... 728 Failure code [CA145] Coolant temp sens low error............................................................................ 730 Failure code [CA153] Chg air temp sensor high error......................................................................... 732 Failure code [CA154] Chg air temp sensor low error.......................................................................... 734 Failure code [CA187] Sens supply 2 volt low error........................................................................... 734 Failure code [CA221] Ambient press sens high error.......................................................................... 736 Failure code [CA222] Ambient press sens low error........................................................................... 738 Failure code [CA227] Sens supply 2 volt high error.......................................................................... 740 Failure code [CA234] Eng overspeed.......................................................................................... 742 Failure code [CA238] Ne speed sens supply volt error........................................................................ 744 Failure code [CA263] Fuel temp sensor high error............................................................................ 746 Failure code [CA265] Fuel temp sensor low error............................................................................. 748 Failure code [CA271] PCV1 short error....................................................................................... 749 Failure code [CA272] PCV1 open error........................................................................................ 750 Failure code [CA273] PCV2 short error....................................................................................... 751 Failure code [CA274] PCV2 open error........................................................................................ 752 Failure code [CA322] Inj #1 (L#1) open/short error.......................................................................... 754 Failure code [CA323] Inj #5 (L#5) open/short error.......................................................................... 756 Failure code [CA324] Inj #3 (L#3) open/short error.......................................................................... 758 Failure code [CA325] Inj #6 (L#6) open/short error.......................................................................... 760 Failure code [CA331] Inj #2 (L#2) open/short error.......................................................................... 762 Failure code [CA332] Inj #4 (L#4) open/short error.......................................................................... 764 Failure code [CA342] Calibration code incompatibility....................................................................... 766 Failure code [CA351] Injectors drive circuit error.......................................................................... 768 Failure code [CA352] Sens supply 1 volt low error........................................................................... 770 Failure code [CA386] Sens supply 1 volt high error.......................................................................... 772 Failure code [CA441] Battery voltage low error.............................................................................. 774 Failure code [CA442] Battery voltage high error............................................................................. 774 Failure code [CA449] Rail press very high error............................................................................. 775 Failure code [CA451] Rail press sensor high error........................................................................... 776 Failure code [CA452] Rail press sensor low error............................................................................ 778 Failure code [CA553] Rail press high error.................................................................................. 778 Failure code [CA554] Rail press sensor in range error....................................................................... 779 Failure code [CA559] Rail press low error................................................................................... 780 Failure code [CA689] Eng Ne speed sensor error.............................................................................. 784 Troubleshooting by failure and error codes, Part 3.............................................................................. 787 Failure code [CA731] Eng Bkup speed sens phase error........................................................................ 789 Failure code [CA757] All continuous data lost error......................................................................... 789 Failure code [CA778] Eng Bkup speed sensor error............................................................................ 790 Failure code [CA1228] EGR valve servo error 1............................................................................... 792 Failure code [CA1625] EGR valve servo error 2............................................................................... 793 Failure code [CA1626] BP valve sol current high error....................................................................... 794 Failure code [CA1627] BP valve sol current low error........................................................................ 796 Failure code [CA1628] Bypass valve servo error 1............................................................................ 797 Failure code [CA1629] Bypass valve servo error 2............................................................................ 798 Failure code [CA1631] BP valve pos sens high error.......................................................................... 800 Failure code [CA1632] BP valve pos sens low error........................................................................... 802 Failure code [CA1633] KOMNET error.......................................................................................... 804 Failure code [CA1642] EGR inlet press sens low error........................................................................ 806 Failure code [CA1653] EGR inlet press sens high error....................................................................... 808 Failure code [CA2185] Throt sens sup volt high error........................................................................ 810 Failure code [CA2186] Throt sens sup volt low error......................................................................... 812 Failure code [CA2249] Rail press very low error............................................................................. 812 Failure code [CA2271] EGR valve pos sens high error......................................................................... 814 Failure code [CA2272] EGR valve pos sens low error.......................................................................... 816 Failure code [CA2351] EGR valve sol current high error...................................................................... 818 Failure code [CA2352] EGR valve sol current low error....................................................................... 820 Failure code [CA2555] Grid htr relay volt low error......................................................................... 821 Failure code [CA2556] Grid htr relay volt high error........................................................................ 822 Failure code [D110KA] Battery relay holding disconnection................................................................... 824 Failure code [D110KB] Battery relay drive short circuit..................................................................... 826 Failure code [D130KA] Neutral safety relay disconnection.................................................................... 828 Failure code [D130KB] Neutral safety relay short circuit.................................................................... 830 Failure code [D161KA] Back-up alarm relay disconnection..................................................................... 832 Failure code [D161KB] Back-up alarm relay short circuit..................................................................... 834 Failure code [D190KA] Engine controller ACC signal cut relay................................................................ 836 Failure code [D190KB] Engine controller ACC signal cut relay short.......................................................... 838 Failure code [D811KR] KOMTRAX controller CAN defective communication........................................................ 840 Failure code [DAFRKR] Machine monitor CAN communication defective communication............................................. 842 Troubleshooting by failure and error codes, Part 4.............................................................................. 845 Failure code [DAQ0KT] Transmission controller internal abnormality.......................................................... 847 Failure code [DAQ1KK] Transmission controller main source voltage reduction................................................. 848 Failure code [DAQ2KK] Transmission controller load voltage reduction........................................................ 850 Failure code [DAQ5KK] Transmission controller sensor 5 V power source (1) power supply source voltage reduction............. 852 Failure code [DAQ6KK] Transmission controller sensor 24 V power supply source voltage reduction............................. 854 Failure code [DAQ7KK] Transmission controller sensor 5 V power supply source (2) power source voltage reduction............. 855 Failure code [DAQ9KQ] Transmission controller type collation (Type select signal inconsistency)............................. 856 Failure code [DAQRKR] Transmission controller CAN defective communication (Abnormality in objective component system)....... 858 Failure code [DAQSKR] Transmission controller S-NET defective communication (Abnormality in objective component system)..... 860 Failure code [DB2RKR] Engine controller CAN defective communication......................................................... 862 Failure code [DB30KT] Steering controller abnormality in controller......................................................... 864 Failure code [DB31KK] Steering controller main power supply source voltage reduction........................................ 866 Failure code [DB32KK] Load power source of steering controller power source voltage drop.................................... 868 Failure code [DB35KK] Steering controller sensor 5 V power source (1) power source voltage drop............................. 870 Failure code [DB36KK] Steering controller sensor 24 V power supply source voltage reduction................................. 872 Failure code [DB37KK] Steering controller sensor 5 V power source (2) power source voltage drop............................. 874 Failure code [DB39KQ] Steering controller type collation (Type select signal inconsistency)................................. 876 Failure code [DB3RKR] Steering controller CAN defective communication (Abnormality in objective component system)........... 878 Failure code [DB3SKR] Steering controller S-NET defective communication (Abnormality in objective component system)......... 880 Failure code [DD12KA] Shift up switch disconnection......................................................................... 882 Failure code [DD12KB] Shift up switch short circuit......................................................................... 884 Failure code [DD13KA] Shift down switch disconnection....................................................................... 886 Failure code [DD13KB] Shift down switch short circuit....................................................................... 888 Failure code [DD14KA] Parking brake lever switch disconnection.............................................................. 890 Failure code [DD14KB] Parking brake lever switch short circuit.............................................................. 892 Failure code [DDB9L4] Reverse switch disagreement........................................................................... 894 Failure code [DDK3L4] Forward switch disagreement........................................................................... 895 Failure code [DDK5KA] Gearshift switch disconnection........................................................................ 896 Failure code [DDK5KB] Gearshift switch short circuit........................................................................ 897 Failure code [DDN7KA] Blade pitch switch disconnection...................................................................... 898 Failure code [DDN7KB] Blade pitch switch short circuit...................................................................... 900 Failure code [DDN9KA] Blade tilt switch disconnection....................................................................... 902 Failure code [DDN9KB] Blade tilt switch short circuit....................................................................... 904 Failure code [DDNBLD] Ripper lift raise oil pressure switch is kept ON for long time........................................ 906 Failure code [DDNCLD] Ripper lift lower oil pressure switch is kept ON for long time........................................ 907 Failure code [DDNDLD] Ripper lift tilt-in oil pressure switch is kept ON for long time...................................... 908 Failure code [DDQ2KA] Parking brake lever switch disconnection.............................................................. 910 Failure code [DDQ2KB] Parking brake lever switch short circuit.............................................................. 912 Failure code [DDQ2L4] Parking brake lever switch disagreement............................................................... 914 Failure code [DDT5KA] Neutral switch disconnection.......................................................................... 915 Failure code [DDT5KB] Neutral switch short circuit.......................................................................... 916 Failure code [DDT5KQ] Lever specification selection (Model selection signal disagreement)................................... 917 Failure code [DGS1KX] Hydraulic oil temperature sensor input signal is out of normal range.................................. 918 Troubleshooting by failure and error codes, Part 5.............................................................................. 921 Failure code [DGT1KA] Power train oil temp sensor disconnection............................................................. 924 Failure code [DGT1KX] Power train oil temp sensor out of input signal range................................................. 926 Failure code [DH21KB] Work equipment pump oil pressure sensor short circuit................................................. 928 Failure code [DH22KA] Work equipment pump oil pressure sensor disconnection................................................. 930 Failure code [DH22KB] Work equipment pump oil pressure sensor short circuit................................................. 932 Failure code [DHH3KA] HSS pump oil pressure sensor A disconnection.......................................................... 934 Failure code [DHH3KB] HSS pump oil pressure sensor A short circuit.......................................................... 936 Failure code [DHH4KA] HSS pump oil pressure sensor B disconnection ......................................................... 938 Failure code [DHH4KB] HSS pump oil pressure sensor B short circuit.......................................................... 940 Failure code [DK10KA] Fuel control dial disconnection....................................................................... 942 Failure code [DK10KB] Fuel control dial short circuit....................................................................... 944 Failure code [DK30KA] Steering potentiometer (1) disconnection.............................................................. 946 Failure code [DK30KB] Steering potentiometer (1) short circuit.............................................................. 948 Failure code [DK30KX] Steering potentiometer (1) out of input signal range.................................................. 950 Failure code [DK30KZ] Steering potentiometer (1) disconnection or short circuit............................................. 951 Failure code [DK30L8] Steering potentiometer (1) analog signals do not agree................................................ 952 Failure code [DK31KA] Steering potentiometer (2) disconnection.............................................................. 954 Failure code [DK31KB] Steering potentiometer (2) short circuit.............................................................. 956 Failure code [DK40KA] Brake potentiometer disconnection..................................................................... 958 Failure code [DK40KB] Brake potentiometer short circuit..................................................................... 960 Failure code [DK55KX] Directional potentiometer out of input signal range................................................... 962 Failure code [DK55KZ] Directional potentiometer disconnection or short circuit.............................................. 963 Failure code [DK55L8] Directional potentiometer analog signals do not agree................................................. 964 Failure code [DK56KA] F-R potentiometer (1) disconnection................................................................... 966 Failure code [DK56KB] F-R potentiometer (1) short circuit................................................................... 968 Failure code [DK57KA] F-R potentiometer (2) disconnection................................................................... 970 Failure code [DK57KB] F-R potentiometer (2) short circuit................................................................... 972 Failure code [DK60KA] Acceleration sensor disconnection..................................................................... 974 Failure code [DK60KB] Acceleration sensor short circuit..................................................................... 976 Failure code [DKH1KA] Pitch angle sensor disconnection...................................................................... 978 Failure code [DKH1KB] Pitch angle sensor short circuit...................................................................... 980 Failure code [DKH1KX] Pitch angle sensor out of input signal range.......................................................... 982 Failure code [DLT3KA] Transmission out-speed sensor disconnection........................................................... 984 Failure code [DLT3KB] Transmission out-speed sensor abnormal................................................................ 986 Failure code [DV00KB] Caution buzzer short circuit.......................................................................... 987 Failure code [DW59KA] Blade dual selector solenoid disconnection............................................................ 988 Failure code [DW59KB] Blade dual selector solenoid short circuit............................................................ 990 Failure code [DW59KY] Blade dual selector solenoid hot short................................................................ 992 Failure code [DW5AKA] Blade pitch selector solenoid disconnection........................................................... 993 Failure code [DW5AKB] Blade pitch selector solenoid short circuit........................................................... 994 Failure code [DW5AKY] Blade pitch selection solenoid hot short circuit...................................................... 996 Troubleshooting by failure and error codes, Part 6.............................................................................. 999 Failure code [DW7BKA] Fan rev EPC disconnection.............................................................................1001 Failure code [DW7BKB] Fan rev EPC short circuit.............................................................................1002 Failure code [DW7BKY] Fan reverse solenoid hot short circuit................................................................1003 Failure code [DWN1KA] HSS pump solenoid right disconnection.................................................................1004 Failure code [DWN1KB] HSS pump solenoid right short circuit.................................................................1006 Failure code [DWN1KY] HSS pump solenoid right hot short.....................................................................1008 Failure code [DWN2KA] HSS pump solenoid left disconnection..................................................................1010 Failure code [DWN2KB] HSS pump solenoid left short circuit..................................................................1012 Failure code [DWN2KY] HSS pump solenoid left short circuit..................................................................1014 Failure code [DWN3KA] Sudden stop prevention solenoid disconnection.........................................................1016 Failure code [DWN3KB] Sudden stop prevention solenoid short circuit.........................................................1018 Failure code [DWN3KY] Sudden stop prevention solenoid hot short circuit.....................................................1020 Failure code [DWN4KA] HSS motor free solenoid disconnection.................................................................1021 Failure code [DWN4KB] HSS motor free solenoid short circuit.................................................................1022 Failure code [DWN5KA] Fan pump solenoid disconnection.......................................................................1024 Failure code [DWN5KB] Fan pump solenoid short circuit.......................................................................1026 Failure code [DWN5KY] Fan pump solenoid hot short circuit...................................................................1028 Failure code [DXH1KA] Lock-up solenoid disconnection........................................................................1030 Failure code [DXH1KB] Lock-up solenoid short circuit........................................................................1032 Failure code [DXH1KY] Lock-up solenoid hot short............................................................................1034 Failure code [DXH4KA] 1st clutch ECMV disconnection.........................................................................1036 Failure code [DXH4KB] 1st clutch ECMV short circuit.........................................................................1038 Failure code [DXH4KY] 1st clutch ECMV hot short circuit.....................................................................1040 Failure code [DXH5KA] 2nd clutch ECMV disconnection.........................................................................1042 Failure code [DXH5KB] 2nd clutch ECMV short circuit.........................................................................1044 Failure code [DXH5KY] 2nd clutch ECMV hot short circuit.....................................................................1046 Failure code [DXH6KA] 3rd clutch ECMV disconnection.........................................................................1048 Failure code [DXH6KB] 3rd clutch ECMV short circuit.........................................................................1050 Failure code [DXH6KY] 3rd clutch ECMV hot short circuit.....................................................................1052 Failure code [DXH7KA] Reverse clutch ECMV disconnection.....................................................................1054 Failure code [DXH7KB] Reverse clutch ECMV short circuit.....................................................................1056 Failure code [DXH7KY] R clutch ECMV hot short circuit.......................................................................1058 Failure code [DXH8KA] Forward clutch ECMV disconnection.....................................................................1060 Failure code [DXH8KB] Forward clutch ECMV short circuit.....................................................................1062 Failure code [DXH8KY] F clutch ECMV hot short circuit.......................................................................1064 Failure code [DXHBKA] Right brake ECMV disconnection........................................................................1066 Failure code [DXHBKB] Right brake ECMV short circuit........................................................................1068 Failure code [DXHBKY] Right brake ECMV hot short circuit....................................................................1070 Failure code [DXHCKA] Left brake ECMV disconnection.........................................................................1072 Failure code [DXHCKB] Left brake ECMV short circuit.........................................................................1074 Failure code [DXHCKY] Left brake ECMV hot short circuit.....................................................................1076 Troubleshooting of electrical system (E-mode)...................................................................................1079 Information in troubleshooting table........................................................................................1081 E-1 The engine does not start...............................................................................................1082 E-2 The preheater does not operate (Manual preheating function).............................................................1085 E-3 The ripper pin puller cylinder does not operate.........................................................................1088 E-4 The machine monitor does not come on at all when the starting switch is turned ON.......................................1090 E-5 When the starting switch is turned ON, the machine monitor completely remains lighted and does not go out...............1092 E-6 When the starting switch is turned ON, the basic check items flash......................................................1093 E-7 While the engine is operating, any caution item flashes.................................................................1094 E-8 While the engine is operating, the emergency warning item flashes.......................................................1097 E-9 While the preheater is operating, the preheating pilot lamp does not come on............................................1102 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)....1104 E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on..................1104 E-12 The engine coolant temperature gauge does not indicate normally........................................................1105 E-13 Indication of the power train (torque converter) temperature gauge is abnormal.........................................1106 E-14 The hydraulic oil temperature gauge does not indicate normally.........................................................1108 E-15 Indication of the fuel gauge is abnormal...............................................................................1109 E-16 Indications of gear speed and engine speed are abnormal................................................................1110 E-17 Indication of the shift mode service meter is abnormal.................................................................1110 E-18 The switch module cannot be operated...................................................................................1111 E-19 The warning lamp does not flash or does not go out.....................................................................1112 E-20 The alarm buzzer does not sound or does not stop.......................................................................1113 E-21 Auto shift down is not possible or is not released.....................................................................1114 E-22 Pivot turn is not possible or is not released..........................................................................1115 E-23 The alarm buzzer cannot be cancelled...................................................................................1116 E-24 The operator mode cannot be operated...................................................................................1118 E-25 The service mode cannot be operated....................................................................................1120 E-26 The back-up alarm does not sound.......................................................................................1122 E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on..........................1124 E-28 The air conditioner does not operate...................................................................................1130 E-29 KOMTRAX system does not operate normally...............................................................................1136 E-30 Fan does not reverse...................................................................................................1138 E-31 Gear cannot be shifted.................................................................................................1140 Troubleshooting of hydraulic and mechanical system (H-mode).....................................................................1143 Information in troubleshooting table........................................................................................1145 H-1 No travel power (No drawbar pull).......................................................................................1146 H-2 Machine does not move (At 2nd or 3rd speed).............................................................................1147 H-3 Machine does not move in any speed range................................................................................1148 H-4 Machine travels only in one direction forward or in reverse.............................................................1149 H-5 When gear is shifted or travel direction is changed, large time lag is made.............................................1150 H-6 Machine does not turn (Not turned rightward or leftward)................................................................1151 H-7 Steering speed or power is low..........................................................................................1152 H-8 Brake does not work.....................................................................................................1153 H-9 Torque converter does not lock-up.......................................................................................1154 H-10 Overheat of power train oil temperature................................................................................1155 H-11 Abnormal sound around HSS pump or HSS motor............................................................................1156 H-12 All work equipment speeds are slow.....................................................................................1157 H-13 Work equipment does not move...........................................................................................1158 H-14 Blade lift speed is slow or lacks power................................................................................1159 H-15 Blade tilt speed is slow or lacks power................................................................................1160 H-16 Ripper lift speed is slow or lacks power...............................................................................1161 H-17 Ripper tilt speed is slow or lacks power...............................................................................1162 H-18 Excessive hydraulic drift of blade lift................................................................................1163 H-19 Excessive hydraulic drift of blade tilt................................................................................1164 H-20 Excessive hydraulic drift of ripper lift...............................................................................1165 H-21 Ripper pin puller cylinder does not work (Giant ripper attachment machine).............................................1166 H-22 Blade pitch does not work (Dual tilt attachment machine)...............................................................1167 H-23 Abnormal sound comes out from around work equipment pump...............................................................1168 H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats)......................1169 H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isloator).....................1169 Troubleshooting of engine (S-mode)..............................................................................................1171 Method of using troubleshooting chart.......................................................................................1173 S-1 Starting performance of engine is poor..................................................................................1176 S-2 Engine does not start...................................................................................................1178 S-3 Engine does not pick up smoothly........................................................................................1182 S-4 Engine stops during operation...........................................................................................1183 S-5 Engine does not rotate smoothly.........................................................................................1184 S-6 Engine lack output (or lacks power).....................................................................................1185 S-7 Exhaust gas is black (incomplete combustion)............................................................................1186 S-8 Oil consumption is excessive (or exhaust gas is blue)...................................................................1188 S-9 Oil becomes dirty quickly...............................................................................................1189 S-10 Fuel consumption is excessive..........................................................................................1190 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................................1191 S-12 Oil pressure drops.....................................................................................................1192 S-13 Oil level rises (Entry of coolant or fuel).............................................................................1194 S-14 Coolant temperature becomes too high (Overheating).....................................................................1196 S-15 Abnormal noise is made.................................................................................................1197 S-16 Vibration is excessive.................................................................................................1198 50 Disassembly and assembly......................................................................................................... 0 General information on disassembly and assembly.................................................................................1201 How to read this manual.....................................................................................................1202 Coating materials list......................................................................................................1204 Special tool list...........................................................................................................1207 Sketchs of special tools....................................................................................................1215 Engine and cooling system.......................................................................................................1225 Removal and installation of engine assembly.................................................................................1226 Removal and installation of radiator assembly (including hydraulic oil cooler assembly and aftercooler assembly)............1231 Removal and installation of hydraulic oil cooler assembly...................................................................1235 Removal and installation of aftercooler assembly............................................................................1237 Removal and installation of radiator guard assembly.........................................................................1239 Removal and installation of fuel tank assembly..............................................................................1244 Removal and installation of engine hood assembly............................................................................1245 Removal and installation of fan drive assembly..............................................................................1247 Removal and installation of fan motor assembly..............................................................................1249 Engine..........................................................................................................................1253 Removal and installation of fuel supply pump assembly.......................................................................1254 Removal and installation of common rail.....................................................................................1258 Removal and installation of cylinder head assembly..........................................................................1261 Removal and installation of fuel injector assembly..........................................................................1272 Removal and installation of engine front seal...............................................................................1276 Removal and installation of engine rear seal................................................................................1280 Power train, Part 1.............................................................................................................1285 Removal and installation of damper assembly.................................................................................1286 Disassembly and assembly of damper assembly.................................................................................1289 Removal and installation of power train unit assembly.......................................................................1294 Disconnection and connection of power train unit assembly...................................................................1299 Disassembly and assembly of PTO assembly....................................................................................1310 Disassembly and assembly of torque converter assembly.......................................................................1317 Disassembly and assembly of torqflow transmission assembly..................................................................1327 Power train, Part 2.............................................................................................................1347 Removal and installation of scavenging pump.................................................................................1348 Disassembly and assembly of HSS case assembly...............................................................................1349 Removal and installation of final drive assembly............................................................................1369 Disassembly and assembly of final drive assembly............................................................................1371 Undercarriage and frame, Part 1.................................................................................................1385 Removal and installation of track frame assembly............................................................................1386 Removal and installation of idler cushion assembly..........................................................................1391 Disassembly and assembly of recoil spring assembly..........................................................................1399 Removal and installation of idler assembly..................................................................................1401 Disassembly and assembly of idler assembly..................................................................................1403 Removal and installation of track roller assembly...........................................................................1406 Disassembly and assembly of track roller assembly...........................................................................1410 Removal and installation of carrier roller assembly.........................................................................1413 Disassembly and assembly of carrier roller assembly.........................................................................1414 Removal and installation of 1st bogie assembly..............................................................................1417 Removal and installation of 2nd, 3rd and 4th bogie assembly.................................................................1429 Disassembly and assembly of bogie assembly..................................................................................1441 Undercarriage and frame, Part 2.................................................................................................1445 Expanding and installing track shoe assembly................................................................................1446 Whole disassembly and whole assembly of track shoe assembly.................................................................1449 Removal and installation of pivot shaft assembly............................................................................1471 Removal and installation of equalizer bar assembly..........................................................................1472 Disassembly and assembly of equalizer bar bushing...........................................................................1475 Hydraulic system................................................................................................................1479 Removal and installation of HSS pump assembly...............................................................................1480 Removal and installation of work equipment and HSS charge pump assembly.....................................................1482 Removal and installation of power train and lubricating oil pump assembly...................................................1484 Removal and installation of HSS motor assembly..............................................................................1486 Removal and installation of fan pump assembly...............................................................................1487 Removal and installation of control valve assembly..........................................................................1489 Disassembly and assembly of work equipment control valve assembly...........................................................1493 Disassembly and assembly of hydraulic cylinder assembly.....................................................................1494 Work equipment..................................................................................................................1503 Removal and installation of blade assembly..................................................................................1504 Disassembly and assembly of ripper assembly.................................................................................1506 Cab and its attachments.........................................................................................................1511 Removal and installation of ROPS guard......................................................................................1512 Removal and installation of operator's cab assembly.........................................................................1513 Removal and installation of operator's cab glass (Stuck glass)..............................................................1515 Removal and installation of floor frame assembly............................................................................1524 Disassembly and assembly of operator’s seat isolator........................................................................1529 Electrical system...............................................................................................................1533 Removal and installation of transmission controller assembly................................................................1534 Removal and installation of steering controller assembly....................................................................1535 Removal and installation of engine controller assembly......................................................................1536 Removal and installation of air conditioner unit assembly...................................................................1537 Removal and installation of monitor panel assembly..........................................................................1540 90 Diagrams and drawings............................................................................................................ 0 Hydraulic circuit diagram.......................................................................................................1543 Hydraulic circuit diagram...................................................................................................1545 Power train hydraulic circuit diagram.......................................................................................1546 Electrical diagrams and drawings................................................................................................1549 Electrical circuit diagram (1/13)...........................................................................................1551 Electrical circuit diagram (2/13)...........................................................................................1552 Electrical circuit diagram (3/13)...........................................................................................1553 Electrical circuit diagram (4/13)...........................................................................................1554 Electrical circuit diagram (5/13)...........................................................................................1555 Electrical circuit diagram (6/13)...........................................................................................1556 Electrical circuit diagram (7/13)...........................................................................................1557 Electrical circuit diagram (8/13)...........................................................................................1558 Electrical circuit diagram (9/13)...........................................................................................1559 Electrical circuit diagram (10/13)..........................................................................................1560 Electrical circuit diagram (11/13)..........................................................................................1561 Electrical circuit diagram (12/13)..........................................................................................1562 Electrical circuit diagram (13/13)..........................................................................................1563 Electrical circuit diagram for inside cab...................................................................................1564 Air conditioner unit electrical circuit diagram.............................................................................1565 Connectors table and arrangement drawing....................................................................................1567
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